Optimal storage of load data for lifetime prediction for equipment used in a well operation

ABSTRACT

An example system for optimal storage of load data for lifetime prediction for a piece of equipment used in a well operation includes a sensor collecting load data of the piece of equipment and a processing device for executing computer readable instructions. The computer readable instructions include: determining a lifetime model for the piece of equipment; calculating a bucket size using one of the lifetime model and a distribution of load data; discretizing a load data spectrum into one or more buckets using the calculated bucket size; assigning the collected load data to the one or more buckets of the load data spectrum; storing the collected load data assigned to the one or more buckets to a memory; and determining a lifetime estimation of the piece of equipment based on the load data assigned to the one or more buckets of the load data spectrum and stored to the memory.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/354,279, entitled “OPTIMAL STORAGE OF LOAD DATA FOR LIFETIMEPREDICTION FOR EQUIPMENT USED IN A WELL OPERATION,” filed Nov. 17, 2016,the disclosure of which is incorporated by reference herein in itsentirety.

BACKGROUND

The present disclosure relates to well operations and, moreparticularly, to determining optimal storage of load data for lifetimeprediction for pieces of equipment (i.e. electronic components) used ina well operation.

Boreholes are drilled into earth formations having reservoirs ofhydrocarbons in order to extract the hydrocarbons through the boreholesto the surface. Various components (e.g., pipe segments, pipe couplings,pipe valves, manifolds, stabilizers, reamers, jars, downhole motors,steering units, formation evaluation sensors, drill bits etc.) connectto a bottom hole assembly which is operated in a borehole from a drillrig at the earth's surface.

Downhole equipment in the boreholes may utilize electronic componentsfor control, monitoring, and communication or other components such asmechanical components, electro-mechanical components, hydraulics,formation evaluation sensors (LWD), measurement while drilling sensors(MWD). Over time, operating conditions (e.g., high temperature, highpressure, excessive acceleration, electrical voltage or current spikes,mechanical stress etc.) downhole may cause damage to or otherwisedegrade components, thereby shortening the useful life of a componentand/or leading to catastrophic failure of a component.

BRIEF SUMMARY

According to aspects of the present disclosure, techniques includingmethods, systems, and/or computer program products for optimaldiscretization of load data for lifetime prediction for a piece ofequipment used in a well operation are provided. An example system mayinclude a sensor collecting load data of the piece of equipment and aprocessing device for executing computer readable instructions. Thecomputer readable instructions include: determining a lifetime model forthe piece of equipment used in the well operation; calculating a bucketsize using one of the lifetime model and a distribution of load data;discretizing a load data spectrum into one or more buckets using thecalculated bucket size; assigning the collected load data to the one ormore buckets of the load data spectrum; storing the collected load dataassigned to the one or more buckets to a memory; and determining alifetime estimation of the piece of equipment based on the load dataassigned to the one or more buckets of the load data spectrum and storedto the memory. The piece of equipment may be replaced or rerun based onthe lifetime estimation.

Additional features and advantages are realized through the techniquesof the present disclosure. Other aspects are described in detail hereinand are considered a part of the disclosure. For a better understandingof the present disclosure with the advantages and the features, refer tothe following description and to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features, and advantagesthereof, are apparent from the following detailed description taken inconjunction with the accompanying drawings in which:

FIG. 1 illustrates a processing system for estimating the lifetime of apiece of equipment used in a well operation according to aspects of thepresent disclosure;

FIG. 2 illustrates a graph of a discretized Arrhenius Curve according toaspects of the present disclosure;

FIG. 3 illustrates a graph of typical distribution of load data, e.g.accelerations according to examples of the present disclosure;

FIG. 4 illustrates a graph of a discretized technique of the typicaldistribution of load data, e.g. accelerations, illustrated in FIG. 3according to aspects of the present disclosure;

FIG. 5 illustrates a graph of a discretized Arrhenius Curve techniqueaccording to examples of the present disclosure;

FIG. 6 illustrates a graph of a discretized Gauss-Distribution accordingto examples of the present disclosure;

FIG. 7 illustrates a graph of a discretized combination technique of thediscretized Arrhenius Curve technique of FIG. 5 and the discretizedGauss-Distribution technique of FIG. 5 according to aspects of thepresent disclosure.

FIG. 8 illustrates a graph of a relative discretization error withrespect to the continuous lifetime model according to examples of thepresent disclosure;

FIG. 9 illustrates a graph of a comparison of consumed lifetimesaccording to examples of the present disclosure;

FIG. 10 illustrates a graph of a comparison of consumed lifetimesaccording to examples of the present disclosure;

FIG. 11 illustrates a flow diagram of a method for identifying anddetermining wear of a component used in a well operation according toaspects of the present disclosure; and

FIG. 12 illustrates a block diagram of a processing system forimplementing the techniques described herein according to examples ofthe present disclosure.

DETAILED DESCRIPTION

Estimating lifetime of a piece of equipment (e.g., communication tools,steering units, and other equipment) used in a well operation reducesfailures at the job site and enables servicing and/or replacement of thepiece equipment at appropriate times. To accurately predict lifetime ofthe piece of equipment, load data is measured and stored on one or morepieces of equipment for loads on the piece of equipment. Examples ofloads may be temperature, accelerations, RPM, torque, bending, pressure,electrical loads, axial and lateral forces and other aspects thatinfluence the lifetime of a piece of equipment.

The storage of load data can be used for lifetime prediction of thepiece of equipment. Lifetime models can be estimated by relating loaddata to equipment failures. The lifetime model provides information onhow likely a piece of equipment fails by applying a particular load. Aninitial lifetime model, also referred to as existing lifetime model, maybe determined by using historical load data. This historical load datarefers to accumulated loads at the event of a failure. The lifetimemodel gives a probability that a failure happens at a specific loadincluding a certain variance which may be caused by slight differencesin the piece of equipment, manufacturing variations, material variationsand other statistical parameters. If the load data is collected inbuckets of the load data spectrum, the load data are averaged in thisbucket or set to the mean value of the bucket. Alternatively, the medianor root square mean or other representative averaging algorithms may beused. A bucket in the load data spectrum is represented by arepresentative value calculated by applying the representative averagingalgorithm on the load data within a bucket. Next, a count of how often aload data is collected in each the buckets occurs. Load data may beeither the historical load data or the new load data. The counts aresaved to a memory. Therefore, an optimal storage of the load data to amemory with limited size, is provided herein.

Different failure mechanisms exist for different types of equipment(e.g., electronics, mechanical parts, hydraulics, connections, formationevaluation sensors (LWD), measurement while drilling sensors (MWD),etc.). Lifetime of the piece of equipment is dependent on the loadcycles and amplitude of the loads. The lifetime is dependent on thefailure mechanism of the part. Whereas electronics are mainly prone tofailures related to temperature and electrical loads (current andvoltage), mechanical integrity is mainly dependent on mechanical loads(e.g. pressure, acceleration, momentums like bending, axial and lateralforces etc.). The present techniques provide for estimating the lifetimeof a piece of equipment used in the well operation to optimizemaintenance cycles or supply of spare parts.

Severe accelerations in drill strings and bottom hole assemblies (BHA)can be caused by different excitation mechanisms like self-excitation,parameter excitation, or forced excitation. Accelerations can bedifferentiated into axial, torsional, and lateral directions. Negativeeffects include reduced rate of penetration, reduced quality ofmeasurements, and downhole failures. Further loads may includetemperature and erosion, pressure, torque, bending.

One approach, as provided herein is to measure lifetime relevant data atthe piece of equipment used in the well operation and store the data ina memory at the piece of equipment. The lifetime relevant datameasurement and/or processing and storage may be performed by usingdedicated electronics modules at or in the piece of equipment and/ordifferent pieces of equipment along a BHA. Application specificintegrated circuits (ASICs) are utilized for this purpose with limitedmemory. ASICs are placed, for example, on multi-chip models (MCMs) in apiece of equipment to store load data for the piece of equipment. Theload data is then used to perform lifetime estimation for the piece ofequipment. This may be, in this example, referred to as lifetimeestimated electronics. Load data of other types of equipment, such asFormation Evaluation sensors (e.g. gamma, acoustic, NMR, nuclear) ormechanical, electro-mechanical or hydraulic pieces of equipment, such asmotors, pumps, valves or bearings, may be measured and/or processed andstored in the memory in the electronics module. Based on the collectedlifetime relevant data and the estimated lifetime, a condition basedmaintenance (CBM) may be performed.

A method is disclosed to discretize a lifetime dependent load dataspectrum, (e.g., temperature and acceleration and the like) in buckets.As used herein, the term bucket refers to a load data interval. Eachbucket is associated to an interval or region of load data. Thedistribution of load data in the bucket could be represented by a numberof load data points within a load data interval or a time spent in aload data interval. The load data interval can be defined by one ormultiple variables, such as temperature, acceleration or pressure. Themethod includes determining optimal bucket sizes in the load dataspectrum dependent on one of a lifetime model and a load datadistribution and other mathematical functions to minimize the failure ofthe lifetime estimation with limited memory. The method can also be usedto estimate the necessary memory for a given tolerance of the lifetimeestimation, also referred to as failure of the lifetime estimation. Fora given maximum failure of the life time estimation the required bucketsizes of the plurality of buckets in the load data spectrum arecalculated. The memory size required to store the distribution of ameasured load data based on the plurality of buckets in the load dataspectrum can be calculated.

The present techniques utilize memory for storing load data in a moreoptimized, efficient, and cost effective manner than existing solutions.For example, existing solutions store load data (e.g., time-based data)without discretizing the load data spectrum into buckets, which usesmore memory size in the memory, thereby increasing memory size and costsassociated therewith. The present techniques, however, use less memorythan existing solutions by determining optimum bucket sizes of the loaddata spectrum and assigning the load data to the buckets, transformingthe load data into a load data distribution or load data profile. Thisdiscretization of the load data spectrum and transformation of load dataimproves the functioning of processing devices by more efficientlyutilizing memory. The present techniques also use time-based-load-dataand transform the time-based load data into buckets and distribution ofload data or load data profiles. Moreover, the present techniquesprovide buckets of different sizes such that smaller buckets are usednear an expected value while larger buckets are used for values inunexpected intervals. This reduces the amount of memory used while alsoproviding more accurate discretizing near expected values. These andother advantages will be apparent from the description that follows.

The teachings of the present disclosure can be applied in a variety ofwell operations. These operations may involve using one or moretreatment agents to treat a formation, the fluids resident in aformation, a wellbore, and/or equipment in the wellbore, such asproduction tubing. The treatment agents may be in the form of liquids,gases, solids, semi-solids, and mixtures thereof. Illustrative treatmentagents include, but are not limited to, fracturing fluids, acids, steam,water, brine, anti-corrosion agents, cement, permeability modifiers,drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc.Illustrative well operations include, but are not limited to, hydraulicfracturing, stimulation, tracer injection, cleaning, acidizing, steaminjection, water flooding, cementing, etc.

By non-limiting example a well operation may also be a drillingoperation in a wellbore. Different pieces of equipment (downhole tools)are combined to become a bottom hole assembly (BHA). The bottom holeassembly being operatively connected to a drill string at the upper end(surface end) and having a drill bit at the lower end (downhole end).The bottom hole assembly containing different type of equipment, such asa mud motor, steering unit, formation evaluation sensors and MWD tools,such as directional, mud pulse communication tools, power generationtools (turbine or battery). The formation evaluation sensors, alsoreferred to as LWD tools, may be resistivity, nuclear magneticresonance, acoustic, downhole sampling, nuclear or pressure testingtools. There may be a bi-directional communication between the bottomhole assembly and surface via mud pulse telemetry including a downlink,electromagnetic telemetry, acoustic telemetry, wired pipe or any othersuitable communication link. Depending on the different pieces ofequipment which are in a particular bottom hole assembly, the differentpurpose of the bottom hole assembly, the different material of thebottom hole assembly or the diameter of a bottom hole, the bottom holeassembly is referred to a bottom hole assembly type.

In examples, a memory may be in and/or on a piece of equipment in thebottom hole assembly. The discretizing may be performed based on loaddata retrieved from the bottom hole assembly after a drilling run atsurface or may be done downhole based on downhole measured load data. Areal time lifetime estimation may be performed in a processor inside thepiece of equipment either downhole or at surface or in a separateprocessor located outside the piece of equipment either downhole or atsurface. In the first case the lifetime estimation is transmitted tosurface. Rerun decisions may be made based on the lifetime estimation.In case the lifetime estimation of the piece is close to, or alreadyexceeded the lifetime of a piece of equipment, the piece of equipmentmay be replaced by another piece of equipment.

FIG. 1 illustrates a processing system 100 for estimating the lifetimeof a piece of equipment used in a well operation according to aspects ofthe present disclosure. The various components, modules, engines, etc.described regarding FIG. 1 may be implemented as instructions stored ona computer-readable storage medium, as hardware modules, asspecial-purpose hardware (e.g., application specific hardware,application specific integrated circuits (ASICs), embedded controllers,hardwired circuitry, etc.), or as some combination or combinations ofthese.

In examples, the engine(s) described herein may be a combination ofhardware and programming. The programming may be processor executableinstructions stored on a tangible memory, and the hardware may include aprocessing device 102 for executing those instructions. Thus a memory104 can store program instructions that when executed by processingdevice 102 implement the engines described herein. Other engines mayalso be utilized to include other features and functionality describedin other examples herein.

Processing system 100 may include the processing device 102, the systemmemory 104, a bucket determination engine 110, a lifetime estimationengine 112, a lifetime comparison engine 114, and a load data repository120. Alternatively or additionally, the processing system 100 mayinclude dedicated hardware, such as one or more integrated circuits,Application Specific Integrated Circuits (ASICs), Application SpecificSpecial Processors (ASSPs), Field Programmable Gate Arrays (FPGAs), orany combination of the foregoing examples of dedicated hardware, forperforming the techniques described herein.

The bucket determination engine 110 discretizes the load data spectruminto a plurality of buckets. The bucket size of each of the plurality ofbuckets is based on the distribution of the load data and/or based on anexisting lifetime model for the piece of equipment as described below.The distribution of load data may be based on historical load data onthe piece of equipment. The historical load data, the distribution ofload data, and other information such as the measured lifetimes ofcomponents achieved in field operations, may be stored in the load datarepository 120, for example.

At block 112, a lifetime estimation is performed from the data stored inthe buckets.

Additionally or alternatively to discretizing the load data spectrum thememory may be compartmentalized into compartments based on one of thelifetime model and the distribution of load data. The size of thecompartments in the memory is based on one of the lifetime model or thedistribution of load data. The distribution of load data is stored tothe compartmentalized memory.

Instead of counting how often a load data is collected in each of theload data interval any other quantity that may represent the weight of aload data interval of the measured load data may be saved to the memory.

According to aspects of the present disclosure, the lifetime ofelectronics for equipment used in well operations can be described bythe Arrhenius curve, as illustrated in FIG. 2. By updating the bucketsizes of the load data spectrum, the overall failure based on thelifetime model is minimized. The load data spectrum in FIG. 2 is thetemperature interval to which the electronics are exposed. Updatingrefers to recalculating the bucket sizes for the plurality of buckets ofthe data spectrum. In particular, the bucket size may be updated suchthat the failure ε_(l) the “left” side of a bucket is the same size asthe failure ε_(r) on the “right” side of a bucket. This failure is thenconstant for each bucket and is therefore limited to this value.

In addition, an expected temperature or a frequency of the temperaturemay influence the size of a bucket. For example, it is not useful tocollect temperature data in buckets at a temperature level that will notbe reached during the expected run. An example of a typical distributionof the accelerations is illustrated in FIG. 3.

In accordance with the acceleration example of FIG. 3, the bucketdetermination engine 110 (FIG. 1) updates the bucket size duringoperation to achieve gRMS values of the acceleration so that each bucketis approximately equal using the following equation.

∫_(x_(i − 1))^(x_(i))p(x)dx = constantwhere x_(i) is the lower (left) bucket limit, x_(i-1) is the upper(right) bucket limit, and p(x) is a probability density function. Theprobability density function p(x) can be derived from a histogram or adistribution of load data or a frequency distribution of load dataaccording to aspects of the present disclosure. The variable x and thelower limit x_(i) and upper limit x_(i-1) can also be a vector ofmultiple variables such as temperature and accelerations. The functionp(x) is a probability density function that may be dependent on multiplevariables. According to FIG. 4, the area (i.e., probability) below eachbucket is equal. Therefore, the bucket size is larger at points of lowprobabilities and higher at points of high probabilities of the expectedacceleration. Every probability density function may be possible. Bynon-limiting example, the probability density function may be a Weibulldistribution, a Gauss distribution, a normal distribution, or anexponential distribution. It may also be possible to fit a polynomial tothe distribution of loads. More than one type of load data may be usedto determine a probability density function, by non-limiting examplethis may be temperature and acceleration or temperature and accelerationand pressure or any other combination of load data, resulting in one,two or multidimensional probability density functions.

By combining the lifetime model and the distribution of load data ofexpected loads, such as historical load data or synthetic load data,optimal bucket sizes may be determined. By way of exemplification, butnot limiting, the probability density function is multiplied with thelifetime model L(x) for every value of the load x. Other mathematicaloperations may as well be suited to combine the distribution of loadwith the lifetime model. In examples, x may be temperature or gRMS levelof accelerations. The function F(x_(i))−p(x_(i))L(x_(i)) reflects thelifetime that is consumed at the load x_(i) according to thedistribution of the load x that gives the number of samples (in thebucket) and the lifetime model L. The lifetime consumed in one bucket isconstant for each bucket of the function F if the distribution of theload data is equal to p(x) and the lifetime model is equal to L(x).

The optimal bucket sizes may be adjacent, or may have gaps between eachother, or may be overlapping. By non-limiting example, it may be of useto store load data from opposite sides of the load data spectrum in onlyone bucket. The buckets do not need to cover the whole load dataspectrum. A particular bucket may have a cross section with anotherbucket. Yet another bucket may be a subset of another bucket.

The lifetime estimation engine 112 determines an lifetime estimation ofthe piece of equipment based on the new load data collected, such asduring the drilling process, stored to the memory after load data isassigned to the discretized load data spectrum. FIGS. 5, 6, and 7illustrate the lifetime estimation, as described below.

FIG. 5 illustrates an example of bucket size according to a lifetimemodel according to aspects of the present disclosure. FIG. 6 illustratesan example of bucket size according to frequency distribution oftemperature according to aspects of the present disclosure. FIG. 7illustrates an example of the combination (e.g., multiplication or anyother suitable mathematical operation) of the lifetime model of FIG. 5and the frequency distribution of the temperature of FIG. 6 according toaspects of the present disclosure.

According to the examples of FIGS. 5-7, a normal distribution isexpected for the distribution of the temperature, and the Arrheniusfactor is used as the expected lifetime model. An expected value of 150°C. and a variance of 10(° C.)² is used for the expected distribution forthe temperature downhole.

Regarding FIG. 5 using the discretized Arrhenius Curve technique, themaximum failure in every bucket is equal for a scalar value. In the casefor continuously increasing slopes, the maximum failure is calculated bythe difference of the value on the right or left side of every bucketthat is given by the continuous Arrhenius Curve and the value that wouldbe calculated by the bucket at the middle of bucket. For a maximum valueof the continuous model and for a minimum value of the continuous model,the failure is indicated by the difference to the value in the middle ofthe bucket or another value taken as reference for this bucket. Themaximum failure in each bucket is not necessarily at the border of thebucket if the lifetime model has maxima and minima in the bucket itself.

Regarding FIG. 6 using the discretized Gauss-Distribution technique, theprobability to hit each bucket is equal in this case. It should beappreciated that the Gauss-Distribution technique is just one possibleexample and other distribution techniques may be implemented instead ofor in addition to the Gauss-Distribution technique.

Regarding FIG. 7 using the discretized combined technique from FIGS. 5and 6, the lifetime consumed in each bucket according to the lifetimemodel and the number of samples expected in one bucket given by theprobability density function is equal. If the load values are equallydistributed, this approach leads to the same result as bucketoptimization by the lifetime model only.

According to aspects of the present disclosure, it may be beneficial tochoose a lifetime for the buckets on the left and right border (lowtemperatures and high temperatures respectively) and not in the middleof the bucket. In some examples, a certain ratio may be used instead ofborders. The ratio may be determined by frequency distribution of loaddata and/or by the lifetime model. According to the frequencydistribution of the temperature, it is meaningful to limit theconsidered temperatures to a specified percentile (e.g. 95% or 99%) ofthe probability density function. Otherwise, the failures become verylarge because the mean value of the buckets (taken for lifetimeprediction) on the border have a very low probability according to thefrequency distribution of this load data. Therefore, values at theborder of this bucket are classified to the middle of the bucket thatresults in a significant failure.

The lifetime comparison engine 114 compares the lifetime estimation ofthe piece of equipment with an expected lifetime of the piece ofequipment. FIG. 8 illustrates one such example comparison for 15buckets. In particular, FIG. 8 illustrates the relative discretizationerror with respect to the continuous lifetime model according toexamples of the present disclosure. The present techniques may alsoapply to a nonlinear dependency of a lifetime model using two variables.For example, failures due to acceleration double if the temperature isincreased by 10° C. In another example, the lifetime model isproportional to temperature multiplied by acceleration. In this case,the lifetime consumed due to temperature and lifetime due toacceleration are not simply summed up and bucket sizes may vary.

The buckets in FIG. 8 have been calculated for an expected value of 150°C. and a variance of the normal distributed temperature values of 10(°C.)². In Monte-Carlo-Simulations (MCS) a variance of 10(° C.)² anddifferent expected values of the mean value of the temperature were used(e.g., 10,000 MCS for each expected value, and normal distributedcalculated random numbers). The failure becomes very small at theexpected value at 150° C. for the Gauss-Distribution technique (FIG. 6)and the combination technique (FIG. 7). The failure becomes large fordifferent expected values of the normal distributed random numbers usingthese techniques.

The failures of the buckets that are calculated by the lifetime modelonly decreases for high temperatures because buckets are closely spacedin this temperature interval for the Arrhenius-Curve technique. For lowexpected values this results in a very large failure (<155° C.). Thisshows that the distribution of the temperatures has to be considered. Inanother example, the buckets of the Arrhenius Curve technique may belimited between specific values, e.g. percentiles, of frequencydistribution of the load data.

In particular, FIG. 8 and FIG. 9 illustrate a parameter study of theexpectation value of an assumed temperature distribution that mightappear in a drilling operation. The expectation value is varied between140° C. and 185° C. FIG. 8 illustrates how the relative discretizationerror develops. Regarding FIG. 8, the Gauss-Distribution line depictsthe development of the relative discretization error when using a bucketdiscretization based on a Gauss-distribution of temperatures. TheArrhenius-Curve line is the development of the relative discretizationerror when using a discretization based on an Arrhenius-Curve as a lifetime function. The Combination line shows the development of therelative discretization error when using a discretization based on thecombination of an Arrhenius life time function and an assumedGauss-distribution of the temperature.

FIG. 9 illustrates how the absolute value of the predicted consumed lifetime varies. The studies are done for three different bucketdiscretization strategies. Discretization according to: a lifetimefunction; a distribution function; and a combination of a lifetimefunction and a distribution function. The cont line depicts thedevelopment of the consumed life time if continuous (analytical)functions for the lifetime function and the seen temperaturedistribution were used. The disc. Arrhenius line depicts the developmentof the consumed lifetime if a discretization based on an Arrheniuslifetime function would be used. The disc. Gauss-Distribution line showsthe development of the consumed lifetime if a discretization based on aGauss-distribution of the temperature would be used. The disc.Combination line illustrates the development of the consumed lifetime ifa discretization based on a combination of an Arrhenius lifetimefunction and a Gauss-distribution would be used.

Another example using 15 buckets is illustrated in FIGS. 9 and 10. Inparticular, FIG. 9 illustrates the comparison of consumed lifetimesaccording to examples of the present disclosure. The calculated consumedlifetime is depicted for the three techniques of FIGS. 5-7 above againstthe exact (continuous) value.

The buckets in FIG. 9 have been calculated for an expected value of 150°C. and a variance of the normal distributed temperature values of 50(°C.)². In Monte-Carlo-Simulations (MCS) a variance of 10(° C.)² anddifferent expectation values along the x-axis of the mean value of thetemperature were used (e.g., 10,000 MCS for each expected value, andnormal distributed calculated random numbers). The continuous (“cont”)line represents the exact value of the consumed lifetime according tothe lifetime model. It is illustrated that the failure is very low forthe buckets calculated using the Gauss-Distribution technique (FIG. 6)and the discretized combination technique (FIG. 7). between 140° C. and165° C.

This is expected because in both techniques the calculated buckets arediscretized according to the frequency distribution of the temperature.It should be appreciated that a higher variance used to calculate theoptimal bucket size than used in the MCS makes the present techniquesrobust for changes of the expected value. The failure of the lifetimeprediction becomes very large above 165° C., because only one bucketexists in this area. The failures of the buckets that are calculated bythe lifetime model only decreases for high temperatures because bucketsare closely spaced in this temperature interval for the discretizedArrhenius Curve technique (FIG. 5).

The buckets in FIG. 10 have been calculated for an expected value of150° C. and a variance of the normal distributed temperature values of50(° C.)². In Monte-Carlo-Simulations (MCS) a variance of 1(° C.)² anddifferent expected values of the mean value of the temperature were used(e.g., 10,000 MCS for each expected value, and normal distributedcalculated random numbers). That means that the distribution of thetemperature is very narrow and the values are nearly equal. The sameresults are achieved for the general trends of the three methods as inFIG. 9. Nevertheless, the buckets can be identified by the steps in thelifetime prediction for the Arrhenius Curve technique. Accordingly, thepredicted lifetime is equal to the theoretical value shown by thecontinuous value line for a mean value of the expected value in themiddle of one bucket and becomes large at the border of the buckets.

As described herein, it should be appreciated that the failure oflifetime prediction can be very high if the bucket location and size isnot updated properly. In some cases, a lifetime model is not existent.Therefore, a higher number of buckets is useful to account foruncertainties. Otherwise, an estimation of the lifetime model is notpossible. The present techniques may also be used to estimate loads orlifetimes for neighboring parts. In examples, the load data could beused and combined with physical models of a drilling system to achievebetter lifetime estimations. A combination of more than one load type(e.g., temperature and acceleration) could be included based on the sameassumptions.

FIG. 11 illustrates a flow diagram of a method 1100 for determining wearof a component used in well operation according to examples of thepresent disclosure. The method 1100 may be performed by a processingsystem, such as the processing system 100 of FIG. 1, the processingsystem 20 of FIG. 12, and/or by another suitable processing system. Themethod 1100 starts at block 1102 and continues to block 1104.

At block 1104, the method 1100 includes storing historical load data(e.g., loads, loads vs. failures, etc.). The historical load data may becollected from field data, laboratory data, synthetic data and/or modeldata.

At block 1106, the method 1100 includes filtering the load data. Theload data may be filtered, such as by a geographic region where the datawere acquired, an equipment type, a bottom hole assembly type (bottomhole assembly build and included equipment types), a drilling bit type,and/or a formation type. Other suitable filtering may also be applied.

At block 1108, the method 1100 includes generating load profiles fromthe historical load data. For example, as illustrated in FIG. 3 and FIG.4 and as described above, histograms representing load profiles aregenerated.

At block 1110, the method 1100 includes determining lifetime models. Thelifetime models are dependent on different loads or load combinations.If lifetime models do not exist, a best guess can be implemented.Lifetime models may be determined using laboratory tests, field tests,and/or using modeling approaches or using a synthetic lifetime model,such as a best guess lifetime model.

At block 1112, the method 110 includes performing a bucketdiscretization of the load data spectrum using the techniques describedherein. This enables optimal bucket sizes to be determined for thevarious buckets so that lifetime data can be stored to memory whileusing a minimum amount of memory.

At block 1114, the method 1100 includes collecting and recordingmeasured loads of a piece of equipment (i.e., electronics, tool, etc.)in the buckets determined at block 1112. The measured loads may includetemperature, accelerations, etc.

At block 1116, the method 1100 includes performing a lifetime estimationfrom the load data assigned to the buckets and stored to the memory. Asdescribed above, FIGS. 5, 6, and 7 illustrate lifetime estimation.

At block 1118, the method 1100 includes comparing the lifetimeestimation to an actual lifetime. As described above, FIG. 8 illustratesone such example comparison. Real lifetime data (the actual lifetime)may be retrieved from the historical load data. FIG. 8 and FIG. 9compare the bucket approach described herein with the exact modelingapproach (continuous). The actual life time can still be different, butit is the same if it is assumed that the continuous life time estimationis equal to the actual consumed life time.

The method 1100 continues to block 1120 and ends.

In some examples, additional processes also may be included, and itshould be understood that the processes depicted in FIG. 11 representillustrations, and that other processes may be added or existingprocesses may be removed, modified, or rearranged without departing fromthe scope and spirit of the present disclosure.

It is understood in advance that the present disclosure is capable ofbeing implemented in conjunction with any other type of computingenvironment now known or later developed. For example, FIG. 12illustrates a block diagram of a processing system 20 for implementingthe techniques described herein. In examples, processing system 20 hasone or more central processing units (processors) 21 a, 21 b, 21 c, etc.(collectively or generically referred to as processor(s) 21 and/or asprocessing device(s)). In aspects of the present disclosure, eachprocessor 21 may include a reduced instruction set computer (RISC)microprocessor. Processors 21 are coupled to system memory (e.g., randomaccess memory (RAM) 24) and various other components via a system bus33. Read only memory (ROM) 22 is coupled to system bus 33 and mayinclude a basic input/output system (BIOS), which controls certain basicfunctions of processing system 20.

Further illustrated are an input/output (I/O) adapter 27 and acommunications adapter 26, also referred to as network adapter, coupledto system bus 33. I/O adapter 27 may be a small computer systeminterface (SCSI) adapter that communicates with a hard disk 23 and/or atape storage drive 25 or any other similar component. I/O adapter 27,hard disk 23, and tape storage device 25 are collectively referred toherein as mass storage 34. Operating system 40 for execution onprocessing system 20 may be stored in mass storage 34. A network adapter26 interconnects system bus 33 with an outside network 36 enablingprocessing system 20 to communicate with other such systems.

A display (e.g., a display monitor) 35 is connected to system bus 33 bydisplay adaptor 32, which may include a graphics adapter to improve theperformance of graphics intensive applications and a video controller.In one aspect of the present disclosure, adapters 26, 27, and/or 32 maybe connected to one or more I/O busses that are connected to system bus33 via an intermediate bus bridge (not shown). Suitable I/O buses forconnecting peripheral devices such as hard disk controllers, networkadapters, and graphics adapters typically include common protocols, suchas the Peripheral Component Interconnect (PCI). Additional input/outputdevices are shown as connected to system bus 33 via user interfaceadapter 28 and display adapter 32. A keyboard 29, mouse 30, and speaker31 may be interconnected to system bus 33 via user interface adapter 28,which may include, for example, a Super I/O chip integrating multipledevice adapters into a single integrated circuit.

In some aspects of the present disclosure, processing system 20 includesa graphics processing unit 37. Graphics processing unit 37 is aspecialized electronic circuit designed to manipulate and alter memoryto accelerate the creation of images in a frame buffer intended foroutput to a display. In general, graphics processing unit 37 is veryefficient at manipulating computer graphics and image processing, andhas a highly parallel structure that makes it more effective thangeneral-purpose CPUs for algorithms where processing of large blocks ofdata is done in parallel.

Thus, as configured herein, processing system 20 includes processingcapability in the form of processors 21, storage capability includingsystem memory (e.g., RAM 24), and mass storage 34, input means such askeyboard 29 and mouse 30, and output capability including speaker 31 anddisplay 35. In some aspects of the present disclosure, a portion ofsystem memory (e.g., RAM 24) and mass storage 34 collectively store anoperating system such as the AIX® operating system from IBM Corporationto coordinate the functions of the various components shown inprocessing system 20.

The present techniques may be implemented as a system, a method, and/ora computer program product. The computer program product may include acomputer readable storage medium (or media) having computer readableprogram instructions thereon for causing a processor to carry outaspects of the present disclosure.

The computer readable storage medium can be a tangible device that canretain and store instructions for use by an instruction executiondevice. The computer readable storage medium may be, for example, but isnot limited to, an electronic storage device, a magnetic storage device,an optical storage device, an electromagnetic storage device, asemiconductor storage device, or any suitable combination of theforegoing. A non-exhaustive list of more specific examples of thecomputer readable storage medium includes the following: a portablecomputer diskette, a hard disk, a random access memory (RAM), aread-only memory (ROM), an erasable programmable read-only memory (EPROMor Flash memory), a static random access memory (SRAM), a portablecompact disc read-only memory (CD-ROM), a digital versatile disk (DVD),a memory stick, a floppy disk, a mechanically encoded device such aspunch-cards or raised structures in a groove having instructionsrecorded thereon, and any suitable combination of the foregoing. Acomputer readable storage medium, as used herein, is not to be construedas being transitory signals per se, such as radio waves or other freelypropagating electromagnetic waves, electromagnetic waves propagatingthrough a waveguide or other transmission media (e.g., light pulsespassing through a fiber-optic cable), or electrical signals transmittedthrough a wire.

Computer readable program instructions described herein can bedownloaded to respective computing/processing devices from a computerreadable storage medium or to an external computer or external storagedevice via a network, for example, the Internet, a local area network, awide area network and/or a wireless network. The network may comprisecopper transmission cables, optical transmission fibers, wirelesstransmission, routers, firewalls, switches, gateway computers and/oredge servers. A network adapter card or network interface in eachcomputing/processing device receives computer readable programinstructions from the network and forwards the computer readable programinstructions for storage in a computer readable storage medium withinthe respective computing/processing device.

Computer readable program instructions for carrying out operations ofthe present disclosure may be assembler instructions,instruction-set-architecture (ISA) instructions, machine instructions,machine dependent instructions, microcode, firmware instructions,state-setting data, or either source code or object code written in anycombination of one or more programming languages, including an objectoriented programming language such as Smalltalk, C++ or the like, andconventional procedural programming languages, such as the “C”programming language or similar programming languages. The computerreadable program instructions may execute entirely on the user'scomputer, partly on the user's computer, as a stand-alone softwarepackage, partly on the user's computer and partly on a remote computeror entirely on the remote computer or server. In the latter scenario,the remote computer may be connected to the user's computer through anytype of network, including a local area network (LAN) or a wide areanetwork (WAN), or the connection may be made to an external computer(for example, through the Internet using an Internet Service Provider).In some examples, electronic circuitry including, for example,programmable logic circuitry, field-programmable gate arrays (FPGA), orprogrammable logic arrays (PLA) may execute the computer readableprogram instructions by utilizing state information of the computerreadable program instructions to personalize the electronic circuitry,in order to perform aspects of the present disclosure.

Aspects of the present disclosure are described herein with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems), and computer program products according to aspects of thepresent disclosure. It will be understood that each block of theflowchart illustrations and/or block diagrams, and combinations ofblocks in the flowchart illustrations and/or block diagrams, can beimplemented by computer readable program instructions.

These computer readable program instructions may be provided to aprocessor of a general purpose computer, special purpose computer, orother programmable data processing apparatus to produce a machine, suchthat the instructions, which execute via the processor of the computeror other programmable data processing apparatus, create means forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks. These computer readable program instructionsmay also be stored in a computer readable storage medium that can directa computer, a programmable data processing apparatus, and/or otherdevices to function in a particular manner, such that the computerreadable storage medium having instructions stored therein comprises anarticle of manufacture including instructions which implement aspects ofthe function/act specified in the flowchart and/or block diagram blockor blocks.

The computer readable program instructions may also be loaded onto acomputer, other programmable data processing apparatus, or other deviceto cause a series of operational steps to be performed on the computer,other programmable apparatus or other device to produce a computerimplemented process, such that the instructions which execute on thecomputer, other programmable apparatus, or other device implement thefunctions/acts specified in the flowchart and/or block diagram block orblocks.

The flowchart and block diagrams in the figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods, and computer program products according to variousaspects of the present disclosure. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof instructions, which comprises one or more executable instructions forimplementing the specified logical function(s). In some alternativeimplementations, the functions noted in the block may occur out of theorder noted in the figures. For example, two blocks shown in successionmay, in fact, be executed substantially concurrently, or the blocks maysometimes be executed in the reverse order, depending upon thefunctionality involved. It will also be noted that each block of theblock diagrams and/or flowchart illustration, and combinations of blocksin the block diagrams and/or flowchart illustration, can be implementedby special purpose hardware-based systems that perform the specifiedfunctions or acts or carry out combinations of special purpose hardwareand computer instructions.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A method for optimal storage of load data for lifetime prediction for apiece of equipment used in a well operation, the method comprising:using a lifetime model for the piece of equipment used in the welloperation; discretizing, by a processing device, a load data spectruminto one or more buckets, the one or more buckets having a bucket size,wherein the bucket size of at least one bucket is based on one of thelifetime model and a distribution of load data; collecting load data ofthe piece of equipment; assigning, by the processing device, thecollected load data to the one or more buckets of the load dataspectrum; and storing, by the processing device, the collected load dataassigned to the one or more buckets to a memory.

Embodiment 2

The method of any previous embodiment, wherein assigning comprisesdetermining a distribution of load data in the one or more buckets.

Embodiment 3

The method of any previous embodiment, wherein using the lifetime modelcomprises using at least one of laboratory tests, field tests, ormodeling approaches.

Embodiment 4

The method of any previous embodiment further comprising updating one ofthe lifetime model, updating the distribution of load data, and updatingthe bucket size for the load data spectrum for the piece of equipment.

Embodiment 5

The method of any previous embodiment further comprisingcompartmentalizing the memory in compartments, wherein the size of thecompartments is based on one of the lifetime model and the distributionof load data.

Embodiment 6

The method of any previous embodiment further comprising determining, bythe processing device, a lifetime estimation of the piece of equipmentbased on the load data assigned to the one or more buckets in the loaddata spectrum and stored to the memory.

Embodiment 7

The method of any previous embodiment further comprising replacing apiece of equipment based on the lifetime estimation.

Embodiment 8

The method of any previous embodiment wherein the distribution of loaddata comprises at least one of a temperature, an acceleration, apressure, a mechanical load, and an electrical load.

Embodiment 9

The method of any previous embodiment wherein the bucket size of one ormore of the buckets varies corresponding to a probability densityfunction.

Embodiment 10

The method of any previous embodiment further comprising filtering thedistribution load data by at least one of a geographic region, a pieceof equipment type, a bottom hole assembly type, a drilling bit type, anda formation type.

Embodiment 11

The method of any previous embodiment wherein storing comprises using amemory located in a bottom hole assembly used in a drilling operation.

Embodiment 12

The method of any previous embodiment wherein updating comprisesminimizing the failure of the lifetime estimation of a piece ofequipment.

Embodiment 13

The method of any previous embodiment wherein the determining isperformed inside a bottom hole assembly.

Embodiment 14

The method of any previous embodiment wherein the determining isperformed outside a bottom hole assembly.

Embodiment 15

The method of any previous embodiment wherein discretizing comprisesestimating a necessary size of the memory based on a given failure ofthe lifetime estimation.

Embodiment 16

The method of any previous embodiment further comprising communicatingthe determined lifetime estimation to a processing device located at asurface of the earth.

Embodiment 17

A system for optimal storage of load data for lifetime prediction for apiece of equipment used in a well operation, the system comprising: asensor collecting load data of the piece of equipment; and a processingdevice for executing computer readable instructions, the computerreadable instructions comprising: determining a lifetime model for thepiece of equipment used in the well operation; discretizing a load dataspectrum into one or more buckets, the one or more buckets having abucket size, wherein the bucket size of at least one bucket is based oneither the lifetime model or a distribution of load data; assigning thecollected load data to the one or more buckets of the load dataspectrum; and storing the collected load data assigned to the one ormore buckets to a memory.

Embodiment 18

The system of any previous embodiment wherein the memory is in the pieceof equipment and the load data are collected at the piece of equipmentinside a bottom hole assembly.

Embodiment 19

The system of any previous embodiment wherein the processing devicedetermines a lifetime estimation of the piece of equipment based on theload data assigned to the one or more buckets and stored to the memory,a communication link communicating the estimated lifetime to the surfaceduring the well operation.

Embodiment 20

The system of any previous embodiment wherein the piece of equipment isa multi-chip module (MCM).

Embodiment 21

A system for optimal storage of load data for lifetime prediction for apiece of equipment used in a well operation, the system comprising: asensor collecting load data of the piece of equipment; and a processingdevice for executing computer readable instructions, the computerreadable instructions comprising: determining a lifetime model for thepiece of equipment used in the well operation; calculating a bucket sizeusing one of the lifetime model and a distribution of load data;discretizing a load data spectrum into one or more buckets using thecalculated bucket size; assigning the collected load data to the one ormore buckets of the load data spectrum; storing the collected load dataassigned to the one or more buckets to a memory; and determining alifetime estimation of the piece of equipment based on the load dataassigned to the one or more buckets of the load data spectrum and storedto the memory, wherein the piece of equipment is replaced or rerun basedon the lifetime estimation.

Embodiment 22

The system of any previous embodiment, wherein the memory is in thepiece of equipment and the load data are collected at the piece ofequipment inside a bottom hole assembly.

Embodiment 23

The system of any previous embodiment further comprising a communicationlink communicating the estimated lifetime to a surface processing devicelocated at a surface of the earth during the well operation.

Embodiment 24

The system of any previous embodiment, wherein the piece of equipment isa multi-chip module (MCM).

Embodiment 25

The system of any previous embodiment, wherein the computer readableinstructions further comprise updating one of the lifetime model,updating the distribution of load data, and updating the bucket size forthe load data spectrum for the piece of equipment.

Embodiment 26

The system of any previous embodiment, wherein the computer readableinstructions further comprise compartmentalizing the memory incompartments, wherein a size of the compartments is based on one of thelifetime model and the distribution of load data.

Embodiment 27

The system of any previous embodiment, wherein the distribution of loaddata comprises at least one of a temperature, an acceleration, apressure, a mechanical load, or an electrical load.

Embodiment 28

The system of any previous embodiment, wherein the computer readableinstructions further comprise filtering the distribution of load data byat least one of a geographic region, a piece of equipment type, a bottomhole assembly type, a drilling bit type, or a formation type.

Embodiment 29

The system of any previous embodiment, wherein the determining thelifetime estimation of the piece of equipment is performed inside abottom hole assembly.

Embodiment 30

The system of any previous embodiment, wherein the determining thelifetime estimation of the piece of equipment is performed outside abottom hole assembly.

Embodiment 31

The system of any previous embodiment, wherein the discretizingcomprises estimating a necessary size of the memory based on a givenfailure of the lifetime estimation.

The descriptions of the various examples of the present disclosure havebeen presented for purposes of illustration, but are not intended to beexhaustive or limited to the embodiments disclosed. Many modificationsand variations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the described techniques.The terminology used herein was chosen to best explain the principles ofthe present techniques, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the techniquesdisclosed herein.

Additionally, the term “about” is intended to include the degree oferror associated with measurement of the particular quantity based uponthe equipment available at the time of filing the application. Forexample, “about” can include a range of ±8% or 5%, or 2% of a givenvalue.

While one or more embodiments have been shown and described,modifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

What is claimed is:
 1. A system for optimal storage of load data for lifetime prediction for a piece of equipment used in a well operation, the system comprising: a sensor collecting load data of the piece of equipment, wherein the piece of equipment is replaced or rerun based on a lifetime estimation; and a processing device for executing computer readable instructions, the computer readable instructions comprising: determining a lifetime model for the piece of equipment used in the well operation; calculating a bucket size using one of the lifetime model and a distribution of load data; discretizing a load data spectrum into one or more buckets using the calculated bucket size; assigning the collected load data to the one or more buckets of the load data spectrum; storing the collected load data assigned to the one or more buckets to a memory; and determining the lifetime estimation of the piece of equipment based on the collected load data assigned to the one or more buckets of the load data spectrum and stored to the memory.
 2. The system of claim 1, wherein the memory is in the piece of equipment and the load data are collected at the piece of equipment inside a bottom hole assembly.
 3. The system of claim 1, further comprising a communication link communicating the estimated lifetime to a surface processing device located at a surface of the earth during the well operation.
 4. The system of claim 1, wherein the piece of equipment is a multi-chip module (MCM).
 5. The system of claim 1, wherein the computer readable instructions further comprise updating one of the lifetime model, updating the distribution of load data, and updating the bucket size for the load data spectrum for the piece of equipment.
 6. The system of claim 1, wherein the computer readable instructions further comprise compartmentalizing the memory in compartments, wherein a size of the compartments is based on one of the lifetime model and the distribution of load data.
 7. The system of claim 1, wherein the distribution of load data comprises at least one of a temperature, an acceleration, a pressure, a mechanical load, or an electrical load.
 8. The system of claim 1, wherein the computer readable instructions further comprise filtering the distribution of load data by at least one of a geographic region, a piece of equipment type, a bottom hole assembly type, a drilling bit type, or a formation type.
 9. The system of claim 1, wherein the determining the lifetime estimation of the piece of equipment is performed inside a bottom hole assembly.
 10. The system of claim 1, wherein the determining the lifetime estimation of the piece of equipment is performed outside a bottom hole assembly.
 11. The system of claim 1, wherein the discretizing comprises estimating a necessary size of the memory based on a given failure of the lifetime estimation. 